Method for producing packing sheet with improved insulation and storage properties

ABSTRACT

Provided is a method for producing a packing sheet with improved insulation and storage properties, which can greatly reduce logistics costs by minimizing a volume during storage and transportation and also greatly increase insulation.

TECHNICAL FIELD

The present invention relates generally to a packing sheet and, moreparticularly, to a method for producing a packing sheet with greatlyimproved insulation and storage properties.

BACKGROUND ART

In general, packing materials are used not only to enhance theappearance of packed goods, but also to protect the packed goods againstexternal impacts. In particular, in packing of electrical and electronicproducts or automobile parts such as, bumpers, fenders, doors, and thelike, a first foaming paper sheet or an air cap wrapping sheet isgenerally used to separate the electrical and electronic parts and theautomobile parts from an inner surface of a box wall inside of a paperbox such that an impact force which may be externally applied to packedgoods is absorbed and alleviated.

In the case of the air cap wrapping sheet, there is a problem in thatthe volume of air caps is inevitably large due to the air caps sealed inunits of cells, causing an excessive increase in logistics costs such astransportation costs.

Meanwhile, in an effort to solve such a problem of the air cap wrappingsheet in the related art, Patent Documents 1 to 3 and the like have beenproposed.

Patent Document 1 (Korean Patent No. 10-1482311) relates to a packingbag with a cushioning function, which includes a first cushioning aircolumn part composed of multiple air columns, a second cushioning aircolumn part composed of multiple air columns and connected to the firstcushioning air column part to form an accommodation space foraccommodating goods, and a tie connected to the first cushioning aircolumn part and/or connected to the second cushioning air column part toclose an entrance of the accommodation space.

Furthermore, Patent Document 2 (Korean Patent No. 10-1351072) relates toa package equipped with a double air bag and a packaging method thereof,the package including an inner cushioning part composed of a pair ofbacking sheets coupled to each other, the inner cushioning part in whichair is filled and forming an accommodating portion for accommodating apackaging object; an outer cushioning part surrounding the innercushioning part and in which air is filled; and an air injection part towhich air is injected through an air inlet, wherein the air injectionpart is configured to communicate with the inner and outer cushioningparts via both an air filling inlet of the inner cushioning part and anair filling inlet of the outer cushioning part, whereby air filling ofthe inner and outer cushioning parts is completed by only one airinjection through the air injection part.

Patent Document 3 (Korean Patent No. 10-0995179) relates to a bendablemulti-sectional cushioning cover bag including a packaging box, a firstair tube, a second air tube, and a light-reflecting sheet. Herein, anend of the second air tube is connected to the first air tube andcommunicates therewith. Furthermore, multiple first cushioning partsprovided at the first air tube and multiple second cushioning partsprovided at the second air tube correspond to each other, and each ofthe second cushioning parts and each of the first cushioning partscorresponding thereto are adhered together by means of heat sealing atrespective three sides thereof, thus forming an accommodation space inwhich goods are mounted.

The packing bag, the package, and the cover bag disclosed in PatentDocuments 1 to 3 can be transported and stored and in a state of notinjecting air and thus are significantly reduced in volume as comparedwith the air cap packing sheet in the related art, resulting in asignificant reduction in logistics costs such as transportation costs.In addition, air can be injected before use to realize a cushioningfunction, thus safely packing goods. Meanwhile, a predeterminedinsulation property is provided by air cells into which air is injected.However, the air cells are welded together, which may cause a problem inthat heat exchange is increased by welded portions, resulting in asignificant reduction in insulation.

DISCLOSURE Technical Problem

Accordingly, the present invention has been made keeping in mind theabove problems occurring in the related art, and an objective of thepresent invention is to provide a packing sheet capable of greatlyreducing logistics costs by minimizing a volume during storage andtransportation, while greatly increasing insulation.

Technical Solution

In order to accomplish the above objective, the present inventionprovides a method for producing a packing sheet with improved insulationand storage properties, the method including:

a) producing a formed film on which convex ridges are formed at aregular interval in a direction from a front side to a rear sidethereof;

b) sealing the ridges by attaching a lower film to a lower side of theformed film, the lower film being configured such that a first endthereof is extended in a first side direction thereof longer than afirst end of the formed film;

c) attaching an upper film onto the sealed ridges of the formed film,the upper film being configured such that a first end thereof isextended in a first side direction thereof longer than the first end ofthe formed film;

d) opening a portion of each of the sealed ridges of the formed film;and

e) sealing second ends of the lower film, the formed film, and the lowerfilm after a fluid in the sealed ridges of the formed film is removed.

Furthermore, a check valve may be provided on an upper surface of thefirst end of the lower film or on a lower surface of the first end ofthe upper film, and the check valve may comprise multiple check valvesthat are provided at a regular interval on the upper surface of thefirst end of the lower film or on the lower surface of the first end ofthe upper film.

The method may further comprise forming an injection space by sealingthe first end of the lower film and the first end of the upper film,except for an injection hole of the check valve.

The formed film may be produced by melt-extruding a thermoplasticsynthetic resin onto a vacuum forming roller having forming grooves thatare formed in an outer circumferential surface thereof at a regularinterval and have a shape corresponding to the ridges. Furthermore, theformed film may be produced by forming a thermoplastic synthetic resinfilm by using a thermoforming roller having forming protrusions that areformed at a regular interval and have a shape corresponding to theridges.

The d) may include cutting and opening the portion of each of the sealedridges of the formed film by using a cutting blade. Furthermore, the d)may include piercing and cutting the portion of each of the sealedridges of the formed film by using a needle.

Furthermore, lower films, upper films, and formed films may be attachedtogether in a state in which the lower films and the upper films arealternately stacked on top of each other with the formed films eachinterposed between the lower films and the upper films, and a checkvalve may be provided on an upper surface of the first end of each ofthe lower films and on an upper surface of the first end of each of theupper films.

Furthermore, gas may be filled in the ridges of the formed film.

Herein, the gas may be air or an inert gas.

Alternatively, a liquid may be filled in the ridges of the formed film.

Herein, the liquid may be water.

Furthermore, a light reflection layer may be provided on an upper sideof the upper film or on a lower side of the lower film, or the lightreflection layer may be provided both on the upper side of the upperfilm and on the lower side of the lower film.

Alternatively, a cover layer may be provided on an upper side of theupper film or on a lower side of the lower film, or the light reflectionlayer may be provided both on the upper side of the upper film and onthe lower side of the lower film.

Advantageous Effects

As described above, the present invention can greatly reduce logisticscosts by minimizing a volume during storage and transportation, whilegreatly increasing insulation.

DESCRIPTION OF DRAWINGS

FIG. 1 is a flowchart schematically showing a method for producing apacking sheet with improved insulation and storage properties accordingto a first embodiment of the present invention.

FIG. 2 is a perspective view schematically showing a formed film.

FIG. 3 is a side view schematically showing a process of producing theformed film by using a vacuum forming roller.

FIG. 4 is a side view schematically showing a process of producing theformed film by using a thermoforming roller.

FIG. 5 is an exploded perspective view schematically showing a state inwhich the formed film, a lower film, and an upper film are separated.

FIG. 6 is an assembled perspective view of FIG. 5.

FIG. 7 is a plan view of FIG. 6.

FIG. 8 is a side view schematically showing a state in which a portionof each ridge of the formed film is cut by using a cutting blade andopened.

FIG. 9 is a side view schematically showing a state in which the portionof each ridge is pierced by using a needle and opened.

FIG. 10 is a side view schematically showing a process of removing airfrom the ridges of the formed film.

FIG. 11 is a plan view schematically showing a state in which secondends of the lower film, the formed film, and the upper film are sealed,and first ends of the lower film and the upper film are sealed.

FIG. 12 is a plan view schematically showing a state in which front andrear ends of the lower film, front and rear ends of the formed film, andfront and rear ends of the upper film are sealed.

FIG. 13 is a side view schematically showing a state in which the lowerfilm, the formed film, and the upper film state are wound on a windingroller after compression.

FIG. 14 is a perspective view schematically showing a state in which airis injected again into the ridges and the ridges is inflated.

FIGS. 15 and 16 are plan views schematically showing another shape ofthe ridge.

FIG. 17 is an exploded perspective view schematically showing multiplelower films, multiple formed films, and multiple upper films accordingto a second embodiment of the present invention.

FIG. 18 is an assembled perspective view of FIG. 17.

FIG. 19 is an assembled cross-sectional view of FIG. 17.

FIG. 20 is an assembled plan view of FIG. 17.

BEST MODE

Hereinafter, exemplary embodiments of the present invention will bedescribed in further detail with reference to the accompanying drawings.It will be understood by those of ordinary skill in the art that variouschanges and modifications may be made therein without departing from thetechnical idea and scope of the present invention and such changes andmodifications belong to the claims of the present invention.

FIG. 1 is a flowchart schematically showing a method for producing apacking sheet with improved insulation and storage properties accordingto a first embodiment of the present invention.

As shown in FIG. 1, the method for producing the packing sheet withimproved insulation and storage properties largely includes a) a formedfilm producing step (hereinafter referred to as ‘step a)’), b) a lowerfilm attaching step (hereinafter referred to as ‘step b)’), c) an upperfilm attaching step (hereinafter referred to as ‘step c)’), d) a ridgeopening step (hereinafter referred to as ‘step d)’), and e) a second endsealing step (hereinafter referred to as ‘ step e)’).

FIG. 2 is a perspective view schematically showing a formed film.

First, as shown in FIG. 2, the step a) is a step of producing the formedfilm 110 on which a ridge 111 is formed.

Multiple ridges 111 convex upwardly of the formed film 110 are formed ata regular interval in a direction from a front side of the formed film110 to a rear side thereof.

FIG. 3 is a side view schematically showing a process of producing theformed film by using a vacuum forming roller.

A method of forming the ridges 111 on the formed film 110 may vary, forexample, the vacuum forming roller 40 as shown in FIG. 3 is used.

The vacuum forming roller 40 has forming grooves 410 that are formed inan outer circumferential surface thereof at a regular interval and havea shape corresponding to the ridges 111. The formed film 110 is producedby melt-extruding a thermoplastic synthetic resin 2 onto the vacuumforming roller 40.

FIG. 4 is a side view schematically showing a process of producing theformed film by using a thermoforming roller.

As another example, as shown in FIG. 4, the formed film 110 is producedby forming a thermoplastic synthetic resin film 4 by using thethermoforming roller 50 having forming protrusions 510 that protrudefrom an outer circumferential surface thereof at a regular interval andhave a shape corresponding to the ridges 111.

FIG. 5 is an exploded perspective view schematically showing a state inwhich the formed film, a lower film, and an upper film are separated,FIG. 6 is an assembled perspective view of FIG. 5, and FIG. 7 is a planview of FIG. 6.

Next, as shown in FIGS. 5 and 6, the step b) is a step of sealing theridges 111 by attaching the lower film 120 to a lower side of the formedfilm 110 by various methods such as adhering, welding, or the like.

A first end of the lower film 120 is extended longer than a first end ofthe formed film 110 in a first side direction of the lower film 120 suchthat the lower film 120 is longer in left and right length than theformed film 110.

Next, as shown in FIGS. 5 and 6, the step c) is a step of attaching theupper film 130 to the sealed ridges 111 of the formed film 110 byvarious methods such as adhering or the like.

A first end of the upper film 130 is extended longer than the first endof the formed film 110 in a first side direction of the upper film 130such that the upper film 130 is longer in left and right length than theformed film 110.

In particular, because the ridges 111 are in a state of being convexlyinflated upwardly of the formed film 110 due to a fluid such as air thatis initially filled in the ridges 111 in the process of attaching thelower film 120 to the lower side of the formed film 110, it is possibleto easily join the upper film 130 to the ridges 111 of the formed film110.

Next, as shown in FIGS. 5 to 7, a check valve 121 is provided on anupper surface of the first end of the lower film 120 or a lower surfaceof the first end of the upper film 130.

One check valve 121 may be provided on the upper surface of the firstend of the lower film 120 or on the lower surface of the first end ofthe upper film 130. However, in order to allow air to be injected againinto the ridges 111 and a space 140 (see FIG. 6) formed between each ofthe ridges 111, as shown in FIGS. 5 to 7, it is preferable that at leasttwo multiple check valves 121 are provided at a regular interval on theupper surface of the first end of the lower film 120 or on the lowersurface of the first end of the upper film 130.

FIG. 8 is a side view schematically showing a state in which a portionof each ridge of the formed film is cut by using a cutting blade andopened.

Next, the step d) is a step of opening the portion of each of the sealedthe ridges 111 of the formed film 110 to remove the fluid such as air inthe ridges 111 to outside of the ridges 111.

In the step d), the portion of each of the ridges 111 is opened byvarious methods. For example, a portion of each of the sealed ridges 111of the formed film 110, for example, a side portion of each of theridges 111 is subjected to cutting C horizontally with the cutting bladeas shown in FIG. 8.

FIG. 9 is a side view schematically showing a state in which the portionof each ridge is pierced by using a needle and opened.

As another example, in the step d), the portion of each of the ridges111, for example, the side portion of each of the ridges 111 issubjected to piercing P with the needle as shown in FIG. 9.

FIG. 10 is a side view schematically showing a process of removing airfrom the ridges of the formed film.

As shown in FIG. 10, when the formed film 110, the lower film 120 andthe upper film 130 are passed between a pair of rotary rollers 11, thefluid such as air in the ridges 111 of the formed film 110 is removed tooutside of the ridges 111 while the formed film 110, the lower film 120,and the upper film 130 are compressed.

FIG. 11 is a plan view schematically showing a state in which secondsends of the lower film, the formed film, and the upper film are sealed,and first ends of the lower film and the upper film are sealed.

Next, as shown in FIG. 11, the step e) is a step of sealing the secondends of the lower film 120, the formed film 110, and the upper film 130by various methods such as adhering, welding, or the like after thefluid such as air in the ridges 111 of the formed film 110 having theopened portions is removed.

Next, as shown in FIG. 11, there is further included an injection spaceforming step (hereinafter, referred to as ‘step f)’) of forming aninjection space 150 by sealing the first end of the lower film 120 andthe first end of the upper film 130, except for an injection hole 121 aof each of the check valves 121, by various methods such as adhering,welding, or the like.

FIG. 12 is a plan view schematically showing a state in which front andrear ends of the lower film, the formed film, and the upper film aresealed.

As shown in FIG. 12, the front ends of the lower film 120, the formedfilm 110, and the upper film 130 are sealed by various methods such asadhering, welding, or the like. Furthermore, the rear ends of the lowerfilm 120, the formed film 110, and the upper film 130 are sealed byvarious methods such as adhering, welding, or the like.

FIG. 13 is a side view schematically showing a state in which the lowerfilm, the formed film, and the upper film are wound on a winding rollerafter compression.

Next, there is further included a winding step (hereinafter referred toas ‘step g)’) of winding the lower film 120, the formed film 110, andthe upper film 130 on an outer surface of the winding roller 20 in aroll type after compression.

On the winding roller 20, the lower film 120, the formed film 110, andthe upper film 130 that are in a state in which the second ends thereofare not sealed are wound, or the lower film 120, the formed film 110,and the upper film 130 that are in a state in which the second endsthereof are sealed are wound.

Through the step g), air in the ridges 111 is removed. This makes itpossible for the packing sheet to be transported and stored in a statein which the volume is minimized, resulting in a significant reductionin logistics costs.

FIG. 14 is a perspective view schematically showing a state in which airis injected again into the ridges and the ridges are inflated.

Next, an operator injects the fluid such as air into the injection space150 through the injection holes 121 a of the check valves 121 with aninjection means such as an injector. As shown in FIG. 14, the fluid suchas air injected into the injection space 150 is injected into the ridges111 having the opened portions and into the spaces 140 formed betweenthe ridges 111.

In particular, because the fluid such as air is injected into the spaces140 formed between the ridges 111, heat exchange due to the spaces 140is prevented, thus preventing insulation of the packing sheet from beingdeteriorated with high efficiency

FIGS. 15 and 16 are plan views schematically showing another shape ofthe ridge.

Next, as shown in FIG. 14, the ridges 111 have a “▬” shape horizontallyextending in a direction from a first side of the formed film 110 towarda second side thereof by a predetermined length, but the presentinvention is not limited thereto. The ridges may have various shapes,for example, as shown in FIG. 15, multiple ridges are arranged in anhourglass shape so as to communicate with each other in multiple rows.

Furthermore, as shown in FIG. 16, a connecting ridge 111 a is providedbetween a ridge 111 of one row and a ridge 111 of an adjacent row andconnects the ridge 111 of one row and the ridge 111 of the adjacent rowto each other, such that the connecting ridge communicates with theridge 111 of one row and the ridge 111 of the adjacent row.

As describe above, the connecting ridge 111 a is provided between theridge 111 of the one row and the ridge 111 of the adjacent row. However,in this case, when any one of the ridges 111 is damaged, a fluid in allthe other ridges 111 as well as in the any one of the ridges 111 isliable to leak out of a packing sheet 10. Accordingly, it is preferablethat the connecting ridge 111 a is not provided.

FIG. 17 is an exploded perspective view schematically showing multiplelower films, multiple formed films, and multiple upper films accordingto a second embodiment of the present invention, FIG. 18 is an assembledperspective view of FIG. 17, FIG. 19 is an assembled cross-sectionalview of FIG. 17, and FIG. 20 is an assembled plan view of FIG. 17.

Next, a method for producing a packing sheet with improved insulationand storage properties according to a second embodiment of the presentinvention is configured in the same manner as that of the firstembodiment except that as shown in FIGS. 17 to 20, the lower films 120,the upper films 130, and the formed films 110 are attached together in astate in which the lower films 120 and the upper films 130 arealternately stacked on top of each other with the formed films eachinterposed between the lower films and the upper films.

Furthermore, the check valves 121 are provided on the upper surface ofthe first end of each of the lower films 120 and on an upper surface ofthe first end of each of the upper films 130.

Next, gas such as air is filled in all of the ridges 111 of the formedfilms 110 as described above, but the present invention is not limitedthereto. Various gases may be filled in the ridges 111, such as an inertgas including nitrogen, argon, krypton, helium, neon, xenon, radon, andthe like, which are not only excellent in insulation and but also stableand do not easily react.

Alternatively, various liquids such as water may be filled in all of theridges 111 of the formed films 110.

Alternatively, in the second embodiment, air is injected into all of theridges 111 of any one of the formed films 110, while the inert gas isfilled in all of the ridges 111 of another one of the formed films 110,such that different gases are alternately filled in the ridges 111 ofthe formed films 110 arranged sequentially from the top to the bottom inone packing sheet 10.

Next, as shown in FIG. 8, a light reflection layer 160 is provided on anupper side of one upper film 130 of the first embodiment or on a lowerside of one lower film 120 of the first embodiment. Alternatively, thelight reflection layer 160 is provided both on the upper side of the oneupper film 130 of the first embodiment and on the lower side of the onelower film 120 of the first embodiment. The light reflection layer isprovided by various methods such as adhering, welding, or the like.

Furthermore, as shown in FIG. 19, the light reflection layer 160 isprovide on the upper side of the upper film 130 located at the uppermostside of the packing sheet of the second embodiment or on the lower sideof the lower film 120 located at the lowermost side of the packing sheetof the second embodiment. Alternatively, the light reflection layer 160is provided both on the upper side of the upper film 130 located at theuppermost side of the packing sheet of the second embodiment and on thelower side of the lower film 120 located at the lowermost side of thepacking sheet of the second embodiment. The light reflection layer isprovided by various methods such as adhering, welding, or the like.

The light reflection layer 160 is provided for reflecting light radiatedon the packing sheet, thus minimizing generation of heat at a hightemperature on the surface of the light reflection layer 160 of thepacking sheet 10 and may be made of various materials such as analuminum foil.

Alternatively, in order to further improve insulation efficiency of thepacking sheet 10, instead of the light reflection layer 160, a coverlayer 170 composed of any one of a paper layer, a non-woven layer, and awoven layer is provided by various methods such as adhering, welding, orthe like.

INDUSTRIAL APPLICABILITY

The present invention can greatly reduce logistics costs by minimizing avolume during storage and transportation, while greatly increasinginsulation.

The invention claimed is:
 1. A method for producing a packing sheet withimproved insulation and storage properties, the method comprising: a)producing a formed film on which convex ridges are formed at a regularinterval in a direction from a front side to a rear side thereof; b)sealing the ridges by attaching a lower film to a lower side of theformed film, the lower film being configured such that a first endthereof is extended in a first side direction thereof longer than afirst end of the formed film; c) attaching an upper film onto the sealedridges of the formed film, the upper film being configured such that afirst end thereof is extended in a first side direction thereof longerthan the first end of the formed film; d) opening a portion of each ofthe sealed ridges of the formed film e) allowing the formed film, thelower film, and the upper film to pass between a pair of rotary rollersso as to remove a fluid in the ridges having the opened portions whilecompressing the formed film, the lower film, and the upper film; and f)winding on an outer surface of a winding roller the lower film, theformed film, and the upper film that are in a state in which second endsthereof are sealed, or the lower film, the formed film, and the upperfilm that are in a state in which the second ends thereof are notsealed.
 2. The method of claim 1, wherein a check valve is provided onan upper surface of the first end of the lower film or on a lowersurface of the first end of the upper film.
 3. The method of claim 2,wherein the check valve comprises multiple check valves that areprovided at a regular interval on the upper surface of the first end ofthe lower film or on the lower surface of the first end of the upperfilm.
 4. The method of claim 2, further comprising: forming an injectionspace by sealing the first end of the lower film and the first end ofthe upper film, except for an injection hole of the check valve.
 5. Themethod of claim 1, wherein the formed film is produced by melt-extrudinga thermoplastic synthetic resin onto a vacuum forming roller havingforming grooves that are formed in an outer circumferential surfacethereof at a regular interval and have a shape corresponding to theridges.
 6. The method of claim 1, wherein the formed film is produced byforming a thermoplastic synthetic resin film by using a thermoformingroller having forming protrusions that are formed at a regular intervaland have a shape corresponding to the ridges.
 7. The method of claim 1,wherein the step d) includes: cutting and opening the portion of each ofthe sealed ridges of the formed film by using a cutting blade.
 8. Themethod of claim 1, wherein the step d) includes: piercing and openingthe portion of each of the sealed ridges of the formed film by using aneedle.
 9. The method of claim 1, wherein a light reflection layer isprovided on an upper side of the upper film or on a lower side of thelower film, or the light reflection layer is provided both on the upperside of the upper film and on the lower side of the lower film.
 10. Themethod of claim 1, wherein a cover layer is provided on an upper side ofthe upper film or on a lower side of the lower film, or the lightreflection layer is provided both on the upper side of the upper filmand on the lower side of the lower film.